Relay



Feb, 22, 1944. H. E. BUCKLEN RELAY Filed Jan.4 8. 1941 42 sheets-sheet 2 BY /WKMW ATTORNEY.

Patented Feb. 22, 1944 UNITED STATES PATENT OFFICE RELAY Herbert E. Bucklen, Elkhart, Ind.

Application January 8, 1941, Serial No. 373,597

15 claims. (ci. ,zoo-111i This invention relates to relays, and more particularly is concerned with relays of the type in which the contacts are enclosed Within a Sealed metal envelope which has been evacuated and nlled with an inert atmosphere, such as hydrogen under pressure or the like.

One object of the present invention is to provide a cup-shaped metal envelope in which is inserted the displacer and ceramic insert which carries the electrode or contact means. A suitable resilient sealing member is compressed into the open end of the envelope and is sealed into position to prevent leakage of gas or moisture therepast by means of an insulating compression member retained under the spun-over edge of the envelope.

Another object of the present invention is to form the envelope of a non-magnetic steel, such as an austenitic steel or the like, whereby the coil for actuating the relay can be disposed directly about the envelope and yet the envelope will not have the undesirable characteristic of retaining magnetism in the relay such as to slow down the making and breaking of the circuit due to residual magnetism retained by the envelope.

Still another object of the present invention is to provide a construction in which a flexible bridging member is carried by the displacer and is adapted to bridge across two or more contacts within the envelope for completing a circuit through the switch. Such a relay is of distinct value for use as a motor starting relay or the like, and it is contemplated within the present invention to provide a motor starting switch or relay capable of use for either a single or a, polyphase motor.

Another feature of the present invention is the provision of a construction in which a wiping contact is provided between the contact making parts of the relay to maintain these contacts clean and bright,

The evacuation of the envelope and its subsequent lling with an inert gas or a reducing atmosphere under pressure, such as hydrogen, is of distinct advantage in removing all impurities, occluded gases or the like from the interior of the switch and then lling the same with an atmosphere under pressure that will prevent oxidation of the contact surfaces and will maintain them free from rust or corrosion so that the contact resistance through the relay will always ren'iain substantially constant.

Other objects and advantages of the present invention will appear more fully from the following detailed description which, taken in conjunction with the accompanying drawings, will disclose to those skilled in the art the particular construction and operation of a preferred form'of the present invention.

In the drawings:

Figure 1 is a sectional view through a motor starter relay embodying the present invention; -'Figure 2 is a sectional view taken substantially on line 2-2 of Figure-1;

Figure 3 is a sectional view taken substantially on line 3-3 of Figure 1;

Figure 4 is a sectional view through a modied form of relay;

Figure 5 is a modified view of another form of relay construction embodying the present invention;

Figure 6 is a'sectional view taken substantially on line 6 6 of Figure 5;

Figure 7 shows a still further modified construction in which the displacer is insulated from the envelope;

Figure 8 is a sectional View taken on line 8-3 of Figure 7;

Figure 9 is a detail View of a certain form of contact arrangement; and

Figure 10 is a sectional view through a still further modified construction in which the atmosphere within the envelope is employed as a gas blast at the point ci arcing during breaking of the circuit.

Referring now in detail to the drawings, I have disclosed in Figure 1 an envelope 5 which is provided with the small diameter portion 6 having the closed end in which is welded the tubulation I provided for the purpose of evacuating the envelope after the parts have been assembled into position, The large cylindrical portion 8 of the envelope is joined to the small diameter portion of the envelope by afrustoconical shoulder 9 which forms a seat for the ceramic insert I0 extending into the envelope. The insert It is provided with a bore I 2 and with an enlarged outwardly opening counterbore I3 over which is disposed a disc I4 carrying a projecting electrode shank I5. The disc M is preferably provided with a face portion I9 of highly conductive material, such as silver or the like, and is adapted to have contact engagement with the ange portion Il of a contact member I8 disposed on the radial shoulder between the bores I2 and I3 of the insert. The contact portion I8, as shown in Figure 2, is arcuate in shape and has the arcuate flange portion I9 which joins the contact surface with the flange I'I to provide for contact to the electrode disc.

Also mounted on the shoulder between the bores I2 and I3 is a second contact member 25, also of arcuate form, which is spaced from the contact I3 by the arcuate segments 2li of the insert. The contact member 20 has a downwardly projecting portion 23, which terminates in a frusto-conical annular flange portion 24 interposed between the end of the, insert and the shoulder S, and having electrical contact with the envelope 5. Thus it will be seen that the contact 20 is connected to the envelope 5, while the Contact I3 is connected to the electrode I4. Closing of the circuit between these two contacts therefore results in closing of the circuit through the relay. I

The rear portion of the electrode disc i4 isreceived within an axial recess formed in the resilient gasket 25, which gasket has a skirt portion 25 engaging about an annular shoulder formed at the outer end of the insert I0. The gasket 25 is compressedJ in position by means of an insulating compression member 2T which is held beneath a retaining ring 28v by spinning over the end 23 of theA envelope. Preferably, the compression-'member r2l! has an axially projecting cylindrical extension about the electrode shank for radially insulating the shank I from the spun over edge 23.

Mounted about the lower end ofy the reduced portion 6 of the envelope is the actuating coil 30, which coil is connected to a suitable actuating circuit. The reduced' portion of the` envelope` is adapted toreceive for axial sliding movement therein the displacer member 32 which is normally biased upwardly bymeans of a coil spring 33 disposed within the closed end oiv the envelope. The displacerV 32 has limited clearance with respect to the defining walls of the portion 6 of the envelope, and the upper end thereof is adapted to engage an annular rubber disc or bumper 33 for stopping its upward movement. Screwed into the upper end of the displacer 32 is the stem 34 which extends upwardly through the bore I2 oi? the insert, and' at its upper end?, carries an umbrella-shaped contact member 35l suitablyA insulated bythe insulating means 36 from the stem. The contact member 35, as shown more clearly in Figure 3, comprises an annular dish-shaped contact member backed up by a resilient actuating spring-like member, both of these members being provided with radial slots 31 toV provide for exibility oi the contact fingers so that any unevenness of the contact surfaces I3v and 20 will be accommodated by the flexibility of the bridging contact member carried by the post 34.

It will be apparent that with this construction the operation of the relay-'is independent of the rotated position ofthe displacer 32, since the Contact member'- 35 can be in any rotatedy position and willV still effect the desired contact engagement between the contacts I3 and 2G. When the coil 30 isenergized, the displacer 32 is drawn downwardly against the pressure of spring 33, thereby forcing the contact fingers 35 rmly onto the contact surfaces I3 and 29. This closes the circuit through the relay. The use of spring-like contact fingers produces a wiping action, insuring that the contact surfaces will be maintained clean. Upon de-energization of the coil 3l), the spring 33 forces the displacer upwardly, thereby providing a snap action breaking oi the circuit between the contacts I8 and 20.

The tubulation 'I is employed after the insert and electrode assembly have been sealed in position in the end of the switch with the displacer in position. This tubulation is then connected to a source of vacuum and the entire inside of the envelope is subjected to a vacuum. Preferably, some heat is applied during this period to drive off any occluded gases or moisture. The tubulation 'l' is then connected to a source of hydrogen gas under pressure, and the interior of the envelope iilled with such gas at a pressure of from 2 to 3 atmospheres. While this pressure is maintained, the tubulation is pinched closed and welded, thereby effectively sealing the envelope against escape of the gas. The metal parts orf the construction may be hydrogen annealed if desired to drive oii any impurities therein, and to ll the pores with hydrogen, whereby the metal will be saturated, and consequently there will be little or no dissipation of the hydrogen gas through the pores of theV envelope when the switch has been assembled and sealed.

In Figure 4 I have disclosed a modied construction embodying the same general principles. The envelope. lh in this form of the invention hasthe enlarged vend portion liz joined thereto by the conical shoulder 133.. Disposed within the reducedl portion of the envelope lill is a displacer fill which preferably is provided withcircumferentially spaced longitudinally directed flutes 45, these. iiutes providing for passage of gas therethrough so as tov reduce the resistance to mQVement of the displacer 34. The lower end of the displacer isnormally adapted to. rest uDQn a rubbery bumper or cushion 35 disposed in the lower end of the envelope, and preferably of annular form4 surrounding the tubulation l. At its upper end the displacer carries the stem il to which is secured the contact sleeve 43, this sleeve preferably being forrned of material of low electrical resistance which is welded or otherwise suitably secured to the stem 4J. The sleeve i8 may be slotted longitudinally to provide increased flexibility, as described in connection with the contact member 35 of Figure 3, and is adapted to have contact engagement with the conical end 2150i. an electrode carried by the stepped electrodedisc having the projecting shank 52. The head 159 is centered within an axial bore 53 of an insert 55, this insert seating against the shoulder 43 and having a counterbored outer Vend receiving the forward portion of the disc 5i), which is thereby centered therein.

VReceived against the rear face of the disc 5U and having the peripheral ange portion abutting the exposed face of the insert 54 is the resilient gasket member 55 which is held in compressed and sealing engagement with the electrode and the wail of the enlarged portion 42 oi'the envelope by the compression member 56 retained in position by the spun-over end 5l of the envelope. A suitable coil 5B is disposed about the upper end of' the reduced portion of the envelope i8 immediately adjacentthe shoulder 33. Upon energization of' this coil the displacer it is drawn upwardly, moving the sleeve 48 into wiping contact engagement with the head lit, thereby closing the circuit through the relay.

it is to be understood that in both Figures 1 and 2, the envelope. may be formed of an `austenitic steel or a steel having no magnetic retaining characteristics, thereby insuring fast snappy ac- 'engagement The construction shown in Figures and 6 is substantially similar, except that in Figure 5 the enevelope 60 has been inverted with the ceramic insert 62 carried within the lower enlarged end 63 thereof. Immediately above the shoulder 64 of the envelope there is provided the coil 65 for actuating the displacer 66. In this form of invention, the tubulation 1 is disposed at the upper end of the envelope.

Disposed intermediate the insert 62 and the shoulder 64 of the envelope is the frusto-conical contact sleeve 61 having a radially flanged portion 68 to which is welded one end of a coil spring member 69 biased between the ange 68 and the lower end of the displacer 66. The spring 69 is also welded to the lower face of the displacer 66, thereby providing a current conducting path between the envelope 66 and the displacer, which is positive and does not depend upon sliding contact of the displacer with the envelope. The displacer is provided with the longitudinally extending peripheral flutes providing for the passage of air thereby to reduce resistance to movement of the displacer under the action of coil 65. Extending centrally through the displacer is a stem or shank member 12 which projects through the upper end of the displacer, and is locked against downward movement therethrough by means of the lock ring 13. The lower end of t'ie stem 12 is provided with a contact head 14, there being a suitable coil spring 15 biased between the head 14 and the lower face of the displacer 66. This allows for a lost motion connection between the displacer and the head 1t, the spring 15 normally urging the head outwardly away from the displacer. Preferably, this head is formed of a low-resistance contact material, such as silver or a silver alloy.

Seated in the end of the insert 62 is an electrode disc 16 carrying on its face the contact cup 'i1 adapted to be engaged by the contact head 1d. Thus, a wiping, full surface contact engagement can be produced between these contacts, insuring a low resistance circuit through the relay. The electrode 16 is sealed in position by means of a resilient gasket corresponding to that shown in Figure 4 and held in compressed position by the compression member 56 retained under the spun over end 18 of the envelope. This provides a normally open circuit relay which, upon energization of the coil 65, will result in closing of the contact between the relay envelope and the electrode 16. Upon deenergization of the coil. the spring 69 will raise the displacer l66 upwardly to close the open circuit. Any magnetic action between the contacts 14 and 11 will be abruptly broken by reason of the spring connections.

Figure 7 shows a modied construction of a normally open relay in which the envelope 68 corresponds to that shown in Figure 5. Other portions of the construction which are similar have corresponding reference numerals.

In this construction, the ceramic insert 62 is provided with a longitudinal tubular extension which extends substantially to the closed end of the envelope. Within the extension 80 is mounted the displacer 82, which preferably is provided with longitudinal bores or passageways 83 for permitting the passage of gas therethrough to facilitate sliding movement of the displacer. The upper end of the displacer is provided with a vboss or pilot 84 receiving the small end of a helically coiled end 85 which, at its opposite end, is biased against the closed end of the envelope 60. The spring is preferably welded to the displacer pilot 84 and to the end of the envelope, and forms the contact means between the displacer and the envelope. The opposite end of the displacer 82 is normally engaged by one end of a coil spring 86 which, at its opposite end is biased on the inturned radial shoulder 81 of the insert 62. This spring normally urges the relay displacer upwardly against the pressure of spring 85 and maintains the relay in open circuit position. Secured in the lower end of the displacer 82 is the stud 88 carrying a contact head 89 which is adapted to engage the contact head 90 of an electrode member 92 having the projecting shank 93, and sealed in position in the outer end of the insert 62.

Upon energization of the coil 65, the displacer is drawn downwardly against the spring 86 closing the contact between the contact members 89 and 90. Upon deenergization of the coil, the spring 86 moves the displacer B2 abruptly up wardly to break the Contact between the portions 89 and 90.

Figure 9 shows a modiiied type of contact ary rangement in which the contact 96 of the electrode 92 has its face cut off at an angle, indicated at 94. Similarly, the stem 83 has its contact portion 89 provided with a corresponding cut-off surface 95. It will be apparent that upon closing of the circuit between these two contacts, a wiping action will be effected which will maintain the contacts clean and bright.

The structure shown in Figure 10 is similar to that shown in Figure 5, but departs therefrom in that the relay is of the normally closed type. Corresponding reference numerals indicate corresponding parts in these views. The coil in this form of the invention is located adjacent the upper end of the relay and is indicated at 96. Disposed Within the reduced portion of the envelope is the displacer 91 which, in this form of the invention has no ilutes but is provided with a loose nt to facilitate its sliding longitudinally within the envelope. The displacer 91 has an axial bore 98 extending therethrough and opening at its lower end into the threaded sleeve 99, which is also provided with a longitudinal bore, and is also provided at its outer end with the contact sleeve |00, which sleeve is preferably formed of cleaned silver or a similar contact material. The sleeve |00 normally rests against the contact head 102 carried by the electrode 16 and the entire weight of the displacer holds the sleeve and head together to provide a hrm contact therebetween. Upon energization of the coil 96, the displacer 91 is drawn upwardly, causing compression of the trapped gas between the upper end of the displacer and the closed end oi the envelope. While a portion of this gas Inayleak downwardly along the interior wall of the envelope, the major portion is forced downwardly through the bore 98 and acts as an. arc quenching blast being directed outwardly within the sleeve |09 into the annular gap being formed between the sleeve and the contact head |02. tending to quench any arcs that might vbe formed therebetween by breaking of the circuit.

Similarly, when the coil is de-energized, the weight of the displacer 91 causes it to fall downwardly. This results in trapping gas beneath the lower end of the displacer and this gas escapes upwardly past the conical head 102 and into the bore. 98,. thereby; also providing an arcquenching blast te prevent any possibility f pitting or erosion of the contact surfaces.

It is therefore believed apparent that I have provided a novel type of dry-hydrogen lied .relay, it being understood that in each of the forms of the invention disclosed, the tubulation is provided for evacuating the envelope after the parts have been sealed in position and then introducing gas such as hydrogen under pressure thereinto and sealingV the same. It is also to be understood that all of the contact members may have various types of contact material on the surfaces thereof to reduce the contact resistance through the relay.

The present construction lends itself well to an economical manufacture of relay, since the parts are, for the most part, standard production parts conventionally used in metal envelope mercury switches, and can thus be employed with little or no change in the present constructions I am. aware that various changes may be made in certain details of the construction herein shown and described, and I therefore do not intend to be limited except as defined by the scope and spirit ofv the appended claims.

l. A relay comprising av sealed-metal envelope having an insulating insert in one end thereof provided with an axial bore, a radial shoulder in said bore facing said end, an electrode disc closing the outer end of said bore and insulated from said envelope, contact segments on said shoulder connected respectively to said envelope and to said electrode, an axially movable armature in said envelope having an axially projecting stem extending into the open end of said bore, and a resilient contact bridging member on the extending end of said stem adapted to bridge across said segments upon axial movement of said armature in one direction.

2. The relay of claim l further characterized in the provision of spring means in said envelope normally urging said armature toward said insert into open circuit position, and resilient insulating bumper means between said insert and said armature.

3. A relay comprising a metallic envelope having an insulating insert sealed in the open end thereof, said insert having an axial bore closed at its outer end by an electrode disc insulated from said envelope, a pair of contacts supported in insulated relation within the bore of said insert facing said disc and connected respectively to said envelope and said. electrode, an armature axially movable in said envelope and having a reduced portion projecting into said bore, and a resilient contact bridging member carried by said portion and engageable with said contacts upon movement of` said armature away from said insert.

4. A relay comprising a metal envelope having an insulating insert sealed in one end thereof. said insert having an axial bore, an electrode disc closing the outer end of said bore, an axially shiftable armature within said envelope having electrical connection to said envelope, contact means on said disc, and means projecting from said armature through said bore and operable upon movement of said armature to engage said contact means for closing a circuit between said envelope and said electrode disc.

5. The relay of claim 4 further characterized by the provision of a resiliently mounted contact on said projecting means arranged to provide relative movement'between; said armature and contact upon engagement of said contact-with said contact means.

6. The relay of claim 4 wherein said electrical connection comprises a spring connected at one end to said envelope and at the opposite end havingy engagement with said armature.

'7. The relay of claim 4 wherein said armature is longitudinally fluted on its lateral surface.

3. The relay of claim 4 wherein said projecting means has limited motion relative to said armature.

9. In combination, Ya relay comprising a metal envelope, an insulating insert sealed in one end thereof and having an axial bore provided with a radial enlargement at its outer end, an electrode having a disc portion closing the outer end of said bore and provided with a projecting contact disposed in said bore, an armature movable axially in said envelope, metallic means for forming an electrical connection between said armature and said envelope, a coil surrounding said envelope for moving said armature, and axially projecting contact means on said armature extending into said bore and operable upon movement of said armature in one direction to engage said electrode Contact.

l0. The combination of claim 9 wherein said envelope is lled ywith hydrogen gas under pressure7 and said armature is provided with longitudinal passageways for permitting said gas to pass from one end of said armature to the other end thereof upon axial movement of said armature.

ll. In combination, a metal envelope having an openend, a hollow insulating insert seated in said end, anelectrode closing the outer end of said insert, and having an axially projecting contact extending into said insert, an armature having a smooth sliding iit in said envelope, a passageway through said armature, a tubular projection on said armature communicating with said passageway and having an outwardly flared end extending into said insert, said envelope being lled with a reducing gas under pressure, and a coil surrounding said envelope for moving said armature to make and break contact between said electrode contact and said dared end of said extension, said gas being forced through said passageway and tubular projection for arc quenching purposes.

l2. The combination of claim 11 wherein said coil is at a point axially removed from said insert whereby said armature is normally in contact engaging position and is lifted therefrom upon energization of said coil.

13. In combination, a metal envelope having an enlarged open end, a hollow insulating insert sealed in said end, an armature slidable axially within said envelope, a contact fixed in said insert, a contact projection on said armature extending into said insert and engageable with said contact, metallic means for forming an electrical connection between said armature and envelope, and biasing means engaging said armature and normally tending to break said contact engagement.

14. The combination of claim 13 further characterized in the provision of a coil surrounding said envelope and operable todraw said armature into contact engagement against said biasing means.

l5. In combination, a sealed metallic cylindrical chamber formed of non-magnetic material, an armature reciprocable axially within said chamber and formed of a magnetic material, an electrode supported in one end of said chamber in insulated relation to said chamber, contact means carried by said electrode, an axial projection on said armature having a contact at the end thereof, means forming an electrical connection between said chamber and armature including a spring normally biasing said armature in a direction to separate saidcontact and said oontact means, and a coil surrounding said chamber and operable when energized to overcome said biasing means and move said armature to engage said contact and contact means.

HERBERT E. BUCKLEN. 

